Process for mapping off-site piping systems in a refinery and/or petrochemical facility and a system for providing emergency isolation and response in a refinery and/or petrochemical facility

ABSTRACT

A process of mapping piping systems associated with a refinery and petrochemical facilities is disclosed, which maps piping systems, which interconnect facility operating units with other operating units, utilities, distribution facilities and storage units. A system for aiding in the isolation of piping systems, operating units and other facility components is also disclosed. The system includes a search database having representations of the piping systems and its related components. A method of isolating an event within a facility is also disclosed. The method includes identifying the location of an event in the facility, performing a search to identify the impacted piping systems and related components, and identifying measures to isolate the event.

CROSS REFERENCE TO RELATED APPLICATION

The present invention relates to and claims priority to U.S. ProvisionalPatent Application No. 60/843,397, filed on Sep. 11, 2006, entitled “AProcess for Mapping Off-Site Piping Systems in a Refinery and/orPetrochemical Facility and a System For Providing Emergency Isolationand Response in a Refinery and/or Petrochemical Facility.”

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a process of mapping piping systemsassociated with a refinery and petrochemical facilities. In particular,the present invention relates to a process of mapping piping systemsassociated with off-site piping systems, which interconnect facilityoperating units with other operating units, utilities, distributionfacilities and storage units. The present invention further relates to asystem for aiding in emergency isolation of the operating units andother facility components to limit potential damage to the same and theresponse time of refinery and/or petrochemical personnel in the event ofan incident within a refinery or petrochemical facility. The system alsoprovides an effective management tool for off-site piping systems withregard to inspection, maintenance and planning for facilitymodifications, maintenance, upgrades and expansions.

2. Discussion of Related Art

Refinery and petrochemical facilities typically occupy large tracts ofland, which may extend over hundreds of acres or possibly several squaremiles. These facilities include multiple operating units including butnot limited to hydrocracking units, cokers, cat cracking units, andnumerous other processing units. The piping, which interconnects theseoperating units along with storage units or tanks is commonly calledoff-site piping. A typical refinery or petrochemical facility mayinclude a plurality of individual off-site piping lines. For example, itis possible that the facility may have in excess of one hundred (100)different off-site piping lines with an excess of 8000 different pipebranches spread over several square miles. These off-site piping linesmay represent up to several thousand miles or more of piping. Typically,each off-site piping line contains a distinct substance, which isisolated from other discrete substances until processing in a processingunit. These substances may be flammable, combustible and inherentlytoxic. The release of these substances due to a leak or a failure of thepiping lines or an event in a processing unit may pose a hazard tofacility personnel, the environment, the facility in general and thesurrounding community. These individual off-site piping lines will oftenoverlap such that the piping travels along similar paths beforebranching off to the desired facility unit and/or storage facility. Eachoff-site piping line may include one or more off-site piping branches.The piping lines contain various piping objects including but notlimited to pipes (or lines), in-line valves (e.g., regulator valves,shut off valves, diverter valves, etc.), and a variety of other pipingobjects (fittings, connectors, vents, drains, sensors, clamps etc.). Thevalves permit the isolation of operating units, the redirection of thedistinct substances or fluids to other units or tanks, etc.

The off-site piping line travels along a path called a pipeband. Thepipeband includes the piping associated with the off-site piping linesand supporting structures (such as pipeway, sleeperway or pipe rack). Apipeband may include a single off-site piping line or multiple pipinglines. For example, a typical vertical cross section of the pipeband(which is referred to as a “cut sheet”) may reveal as few as one to fivedifferent off-site piping lines or as many as in excess of one hundredfifty (150) different off-site piping lines at multiple levels. It isoften difficult to distinguish individual off-site pipe lines. Given thecomplexity of the facility, the number of different processing oroperating units, and the miles of off-site piping, it is often difficultto quickly identify the contents of any one off-site piping line and theoperating units to which it is connected.

There are times when it is necessary to isolate operating units, otheroff-site piping lines, distribution facilities or tanks or prevent theflow of the substances through the off-site piping lines. This may occurduring the occurrence of an emergency event (e.g., failure of anoperating unit, rupture or failure of a storage tank, rupture of aportion of the off-site piping line, a spill, toxic event, fire and/orexplosion). This may also occur during non-emergency situations (e.g., amaintenance project, a capital project associated with modificationand/or expansion of existing operating units or the addition of anoperating unit, the presence of a crane or other construction equipment,which could destroy or damage a pipeband if the crane topples or fails.)While non-emergency situations provide ample time for planning such thatthe impacted off-site piping systems and the associated operating unitscan be properly located, the emergency event requires rapid response.Rapid response to isolate a failure can prevent and reduce spills andthe subsequent escalation of fires, isolate a failure or spill andminimize injuries to personnel, the environment, potential damage to thefacility and the surrounding community.

Most refineries and petrochemical facilities have a rudimentary form ofidentifying off-site piping lines, but also rely upon the vast knowledgeand experience of its employees to identify off-site piping and thenecessary safety measures in the event that it necessary to isolate aparticular operating unit, tank or off-site piping line. This processcan be extremely time consuming and is subject to human error. It ispossible that the particular individual may or may not be aware of arecent modification to the off-site piping line, the location of allvalves or secondary valves in the event of the failure of the primaryvalve. Furthermore, the knowledgeable individual may not be available,which could result in catastrophic events.

There is a need for a structured process for accurately geographicallycorrect mapping off-site piping lines in refinery and petrochemicalfacilities to provide an accurate representation of the off-site pipingline to aid in the reduction of response time during an emergency eventin a refinery or petrochemical facility. There is a further need for aninteractive on-line system for providing rapid response to emergencyevents using the accurately mapped off-site piping lines.

BRIEF SUMMARY OF THE INVENTION

It is an aspect of the present invention to provide a method for mappingan off-site piping system within a refinery or petrochemical facility.The off-site piping system includes one or more off-site piping lineswhich interconnect various operating units with other operating units,storage units, distribution facilities and the like. Each line includesa plurality of piping and other piping objects including but not limitedto in-line valves (e.g., regulator valve, shut off valves, divertervalves, etc.), and other piping objects (fittings, connectors, vents,drains, sensors, clamps etc.). A distinct substance flows through thepiping. The distinct substance may include but is not limited to naturalgas, high pressure steam, water, crude oil, fresh and foul MEA,petrochemicals and the like. Many of these substances are inherentlyhazardous, either due to their physical condition (e.g., high/lowtemperature, high pressure) or chemical properties (e.g., toxicity,flammability). Located throughout the off-site piping system are one ormore valves, and other piping objects which permit the linking of lines,their operation, and the isolation of the same and the isolation ofstorage facilities and operating units. The facility will containmultiple off-site piping lines. The off-site piping lines are grouped inone or more pipebands traversing the facility. Each pipeband containsone or more individual off-site piping lines.

The method in accordance with one aspect of the present inventionincludes obtaining at least one aerial image or three dimensional imageof the facility. The image may be obtained from aerial photographs ofthe facility. It is also possible to use 3-D laser scanning technologyto obtain a representation of the facility. The at least one imageidentifies the approximate locations of each of the at least oneoff-site pipebands, the locations of each operating unit and the storageunits or tanks and other geographical identifiers. The images furtheridentify the location of facility buildings, streets, access ways,electrical stations, fences, gates, flares and other equipment andlandmarks associated with the facility. The pipebands traversing thefacility are identified. Select roadway intersections within thefacility are located and identified as the prime form of landmarkidentifier. It is contemplated that each of the select roadwayintersections and other landmark identifiers being located in thevicinity of at least one off-site piping line or pipeband.

The method further includes locating and identifying at least onelocation in the facility for graphical cross-sectional representationsor cut sheets of the pipebands, which contain the off-site piping lines.The cut sheets are preferably mounted adjacent the pipeband at or nearan intersection such that they may be readily accessed and viewed byfacility personnel. A cut sheet is prepared or mapped for eachidentified location. Each cut sheet identifies each of the off-sitepiping lines at the location of the cut sheet in addition to otherdescriptive information. The descriptive information may include but isnot limited to the unique identifier, the size of the piping at thelocation, the distinct substance flowing therethrough, the location ofthe closest valve or operating unit, HAZMAT information, Material SafetyData Sheets (MSDS), HAZOP information, line ownership information,inspection information and maintenance information associated with theparticular off-site piping lines. Each cut sheet is assigned a uniqueidentifier for quick reference, such that the cut sheet may be readilylocated and identified within the facility.

The method in accordance with the present invention also includesmapping each off-site piping line. Each off-site piping line is assigneda unique identifier. The mapping of each off-site piping line includestraversing or walking the entire length of the off-site piping line toidentify the location of the off-site piping line with respect to othercomponents contained in the facility including but not limited tooperating units, storage tanks, buildings, fences, gates and otheridentifying features. The mapping of the off-site piping line may alsobe accomplished using 3-D laser scanning technology. Each valve andother piping objects contained within the off-site piping line isaccurately and geographically correctly located, assigned an identifierand included on a representation of the line. Furthermore, additionaldescription information is provided for each piping object. For example,the information may include a description of the object, when it wasinstalled, inspected, etc.

The location of cut sheets with respect to the off-site piping line areidentified and located on the representation of the line. The cut sheetis reviewed to ensure that the line is properly identified and locatedon the cut sheet. The diameter of the piping is also identified on therepresentation. Other information relating to the piping may also beadded to the representation including but not limited to whether or notthe line is insulated. It is also contemplated that other utilitysystems (e.g., power, communications) and other systems (e.g., sewers)traversing the facility may be added to the representations toillustrate their location with respect to the lines.

In accordance with an aspect of the present invention, it iscontemplated that the individual cut sheets and representations of thelines may be set forth in tangible or electronic form. When inelectronic form, it is further contemplated that the cut sheets and therepresentations may be linked such that the representations can beeasily searched in a database to permit a user to easily move from onerepresentation to related representations.

The present invention is also directed to a system for emergencyisolation and response for use in a facility having an off-site pipingsystem. The system enables rapid response to emergency events tominimize the impact on the facility, personnel, the environment and thesurrounding community. The system includes a searchable databasecontaining at least one representation of each off-site piping lineincluding its location within the facility, and at least one cut sheetfor each of the at least one pipeband, wherein each cut sheetillustrates the at least one off-site pipe line extending through thepipeband at the particular location of the cut sheet within thefacility. The system also includes a computer operating unit for storingthe searchable database and retrieving representations and cut sheets.The computer operating unit and the database may be located at thefacility or remotely located off-site. The system further includes atleast one terminal for accessing and displaying representations and cutsheets retrieved by the computer operating unit. The terminals permitthe facility personnel to access and search the database. The databasepermits rapid review of the representation to identify and the displaythe necessary representations for a particular line and cut sheet.

It is another aspect of the present invention to provide a method ofisolating an event in a facility. The event may be an emergency eventrequiring rapid response or a non-emergency event such as a maintenanceprocedure, a planning project or a training operation that involves ormay impact upon an offsite piping band. It is also contemplated that thesystem may be used to isolate an event in on-site piping (i.e., pipingwithin the operating unit) in an operating unit in the facility. Themethod includes identifying the location of the event in the facility.The process of identifying the location of the event includesidentifying one of the pipeband, off-site piping line, a facility unitand a land based identifier to identify the location of the event. Themethod also includes performing a search to identify the pipebands andfacility units impacted by the occurrence of the event. The search isperformed based upon the identification of one of the pipeband, off-sitepiping line, a facility unit and a land based identifier to identify thelocation of the event. The search is conducted using an electronicdatabase of representations and cut sheets for each of the piping lines,which is searchable based upon the identification of one of thepipeband, off-site piping line, a facility unit and a land basedidentifier to identify the location of the event. Finally, the methodincludes identifying measures to isolate the event.

These and other aspects of the invention will become apparent when takenin conjunction with the detailed description and appended drawings.

DESCRIPTION OF THE DRAWINGS

The invention will now be described in conjunction with the accompanyingdrawings in which:

FIG. 1 is an example of an aerial representation of a facilityillustrating a perimeter trace in a mapping system according to anembodiment of the present invention;

FIG. 2 is an example of a graphical representation of the facility ofthe FIG. 1 used in accordance with the mapping system according to thepresent invention;

FIG. 3 is an example of a representation of an off-site piping line;

FIG. 4 is another example of a representation of an off-site piping linehaving a particular off-site piping line highlighted;

FIG. 5 is an example of cut sheet for use in the mapping system inaccordance with the present invention;

FIG. 6 is another example of a cut sheet highlighting the off-sitepiping line of FIG. 4,

FIG. 7 is an illustration of the mapping system according to the presentinvention illustrating an intersection within the facility and thelocations of cut sheets;

FIG. 8 is an isometric illustration highlighting an off-site piping linewithin the facility; and

FIG. 9 is an illustration of the emergency isolation and response systemof a menu for selecting off-site piping line based upon lineinformation;

FIG. 10 is an illustration of the emergency isolation and responsesystem of a menu for selecting off-site piping line based upon facilityintersection information;

FIG. 11 is an illustration of the emergency isolation and responsesystem for the intersection selected using the menu in FIG. 10 havingcut sheet locations and off-site piping lines highlighted;

FIG. 12 is another illustration of FIG. 12 having a particular cut sheetlocation highlighted;

FIG. 13 is an illustration of the emergency isolation and responsesystem of a menu for isolating leaks in accordance with the presentinvention;

FIG. 14 is an illustration of the FIG. 13 having valves for leakisolation highlighted;

FIG. 15 is a schematic diagram of the emergency isolation and responsesystem in accordance with the present invention;

FIG. 16 is an illustration depicting the enlargement of a perimetersearch;

FIG. 17 is an illustration depicting a search performed using the systemof the present invention to identify a pipeband;

FIG. 18 is an illustration depicting the information retrieved from thesearch performed in FIG. 17; and

FIG. 19 is a schematic diagram of the emergency isolation and responsesystem in accordance with another embodiment of the present invention.

In the drawings, like reference numerals indicate corresponding parts inthe different figures.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

The mapping of a refinery/petrochemical facility will now be describedin greater detail in connection with the figures. While the presentinvention will be described in connection with a refinery and/orpetrochemical facility, hereinafter referred to as a facility, asillustrated on the display 140 of the monitor 130 of the system 100, thepresent invention is not intended to be so limited; rather, it iscontemplated that the mapping process described herein may be used inconnection with other facilities, which incorporate off-site piping,other similar piping systems and other structures over a large surfacearea. It is also contemplated that the mapping process described hereinand the system described below maybe used in connection with pipingconnecting refining facilities with petrochemical facilities, otherpipelines, which may be outside of the facility, as well as, theindividual process units and storage units within the facility. Forexample, it is contemplated that the process may be used inpharmaceutical manufacturing facilities, facilities for manufacturinggases and other pipe based facilities.

While facilities may have offsite piping plans and other materialsdetailing the layout of the offsite piping within the facility, theseplans may be outdated and not easily accessible. In order to obtain aproper representation for purposes of mapping the facility in accordancewith the present invention, at least one aerial image or 3-Drepresentation is obtained of the facility and the surrounded area,which provides an accurate and current representation of the facility,the location of the operating units, storage tanks, off-site pipingsystems, building locations and the location of buildings and otherstructures in the surrounding community. The identification of units,tanks, systems and buildings in the facility are necessary to properlymap the off-site piping systems and provide easily identifiable pointsof reference for refinery personnel. The identification of structuresand roadways in the surrounding community is useful in the event that anemergency event occurs at the facility, which may require the evacuationof the surrounding community within a certain radius of the facility.The aerial images or representations should be of sufficient quality andresolution such that the individual operating units, the variousstructures at the facility and the interconnecting pipebands can bereadily identified.

It is preferable that the aerial images of the facility and surroundingcommunity be digitized such that the images can be stored within asearchable electronic database. An example of a digital aerial image isillustrated in FIG. 1. The image can be incorporated into an emergencyisolation and response system 100 illustrated below. The use of anelectronic database 120 will permit easy retrieval and access of theimages when needed for emergency response, planning and other eventswhich require accurate knowledge of each of the components of thefacility. As will become more apparent, the aerial images will provide abackground for the mapping of the off-site piping systems within thefacility.

Returning to the facility mapping process according to the presentinvention, the aerial images are used to identify buildings andoperating units within the facility, as shown in FIGS. 1-4, 9 and 10.Each building and operating unit is identified with an identifier thatis unique for the particular building and/or operating unit. Theidentifier, for example, may be the building name or the commonidentifier for the particular operating unit (e.g., the “Alky Unit” orthe “South Crude Unit”). Storage units are also identified and assignedan identifier that is unique to each storage unit. The roadways 20 andaccess routes within the facility are also identified. A displayillustrating roadways is depicted in FIGS. 7 and 11-14. Theintersections of the roads and access routes are identified. While it isnot necessary, it is preferable that each of the intersections isprovided with an identifier that is unique to the particularintersection. Intersections that are located in the vicinity of anoperating unit, a storage facility or off-site piping must beidentified. The identification of intersections provides points ofreference for communications between facility personnel and otherresponding personnel in the event of an emergency or non-emergencyevent.

A plurality of pipebands traverses the facility. Each of the pipebandscontains one or more off-site piping lines, which contain the pipingwhich interconnects the operating units contained in the facility withother operating units, storage tanks, distribution facilities and otherprocessing equipment. A representative example of a pipeband is shown inFIGS. 5 and 6. The pipebands may contain several thousand miles ofoff-site piping. Each pipeband 10 includes at least one off-site pipingline 11. It is possible that a pipeband may contain well in excess ofone hundred fifty (150) separate off-site piping systems. Each off-sitepiping line transports a discrete substance in either liquid or gaseousform including but not limited to hydrogen gases, oxygen, steam, water,crude oil, paraffins, petrochemicals and the like. It is contemplatedthat any number of off-site piping lines may be contained in a givenpipeband. It is also contemplated that a particular off-site piping linemay travel through one or more pipebands as it traverses the facility.It is important to know the identity of the discrete substance flowingthrough the piping lines and the components connected thereto at anylocation within the facility.

In accordance with the present invention, locators are locatedthroughout the facility adjacent intersections and at otherpredetermined locations to provide an identification to facilitypersonnel, of which off-site piping lines are located at a particularlocation. The locators are chosen based upon proximity to intersections,access ways and other geographically significant identifiers. Thelocators comprise a cross-sectional representation of the pipeband atthat location. This cross-sectional representation is hereafter referredto as a cut sheet 5, as shown for example in FIGS. 5 and 6. Each cutsheet provides a representation of all of the off-site piping linescontained within a particular pipeband at the location of thatparticular cut-sheet. The location of each off-site piping line withinthe pipeband is illustrated in addition to the relative size of thepiping associated with each off-site piping line. As shown in FIGS. 5and 6, the piping lines 11 have different diameters. Furthermore, thediameter of a specific piping line may vary. Each off-site piping lineis separately labeled with a unique identifier for identificationpurposes. The cut sheet 5 also includes a directional indicator 51 suchthat the facility personnel can properly orient themselves when viewingthe cut sheet and its associated pipeband. Each pipeline in the vicinityis labeled with the identification provided on the cut sheet such thatthe facility personnel can readily locate the piping lines 11 in thepipestand. For purposes of identification, the unique identifierassigned to a particular off-site piping line is consistently usedthrough out the facility. As such, if a particular off-site piping linetraverses multiple cut sheets, the same identifier will be used torepresent that particular off-site piping line on each cut sheet. Theparticular location of the off-site piping line and the graphicaldepiction of the size of the piping may vary based upon the location ofthe piping within the pipeband at the particular location and the sizeof the piping at that location.

It is contemplated that the cut sheets 5 may be provided on-site inaccordance with the present invention and may make take one of severalforms. The cut-sheet may take the form of a hard copy, or a hard copy ofan electronic drawing. The hard copy may be located in an appropriatemounting assembly to permit easy viewing by the facility personnel, yetbe protected from prolonged exposure to the environments. It may also beilluminated for night viewing. The cut sheet can be updated and replacedwhen necessary (e.g. the pipeband is modified to remove or add off-sitepiping lines). It is also contemplated that the cut sheet may beelectronically displayed on a display monitor, which is part of theresponse system 100. The monitor may be a touch screen that permitsaccess to the cut sheet and the representations of the off-site pipinglines associated with that cut sheet. The monitor may be connected to acentral computer unit 110 containing a database 120. Any updates orrevisions to the cut sheet may be automatically pushed to and displayedat the location corresponding to the particular cut sheet. With sucharrangement, it is contemplated that the display panel may beinteractive such that the facility personnel can identify the particularsubstance flowing through the off-site piping, the status of eachoff-site piping line (i.e., whether or not such piping line isoperational or not in use) and the operating units and other componentslinked to the specific off-site piping system. It is furthercontemplated that a transmitter or transponder may be located at or nearthe location of each cut sheet. Instead of providing a physical copy ofthe cut sheet or a display monitor for viewing the cut sheet, a signalidentifying the cut sheet can be transmitted to a hand held device, pdaor computer. The hand held device, pda or computer would recognize theparticular signal and display the necessary cut sheet for viewing by thefacility personnel. It is also contemplated that a bar code may beprovided at a location of each cut sheet. Facility personnel having anappropriate handheld reader and display can scan the bar code to displaythe relevant cut sheet. It is also contemplated that each pipe line 11within the pipe band may be labeled with an appropriate bar code suchthat facility personnel can access the representation and descriptiveinformation for a specific pipe line 11. The scanned information can betransmitted to the user such that the user can view the representationfor the pipeline and notify factory personnel of the appropriatemeasures.

Each cut sheet is created by either facility personnel and/ordraftspersons who prepare the diagram of the cut sheet at the particularlocation of the cut sheet. Facility personnel then identify each of theindividual off-site piping lines at the location of the cut sheet. It iscontemplated that the cut sheets may be created using any one of severalknown techniques. The cut sheet may be prepared as a paper drawing. Itis also contemplated that the cut sheets may be prepared electronicallyusing CAD based systems or any other system capable of creatingelectronic drawings. While paper drawings may be acceptable, anelectronic cut sheet has its advantages. Multiple hard copies can bemade, updates can be easily performed. The electronic versions may belinked to other cut sheets and drawings of off-site pipe lines, asdiscussed in greater detail below. Each cut sheet is preferably createdon site and crosschecked for accuracy.

Once the location of cut sheets are identified, the mapping ofindividual off-site piping lines can be accomplished. Given the size ofrefinery and petrochemical facilities, the number of individual off-sitepiping lines connecting the operating units and the miles of pipingpresent, the mapping of the individual off-site piping lines can be acomplex, labor intensive and time consuming process, but it is anessential part of maintaining the integrity and functionality of afunctional mapping system. Each off-site piping line is mapped in asimilar manner. A starting point for each off-site piping line isdetermined. The starting point may be located at a storage tank, aparticular operating unit or other unit. The length of each off-sitepiping line is then traversed or walked. Along the length of the line,the diameter of the piping is tracked, the specific location of everyvalve, diverter, connection, other piping objects, and connections tooperating units are identified. The location of each cut sheet throughwhich the piping passes is also identified. Using this information, arepresentation of each off-site piping line is created.

The representation may be created in one of several ways. For example,the representation may be drawn by hand, created electronically using aportable computer or other appropriate device. Facility personnel maycreate a hand drawn image or a CAD image that is later electronicallytransferred and entered into the database 120. It is also contemplatedthat the creation of a hand drawn image may be omitted using a portablecomputer or other appropriate device to create a representation of thepiping line as the facility personnel walk the particular off-sitepiping line. An electronic representation of the off-site pipeline maybe stored in a database 120. Whether the representation is created byhand or using an appropriate electronic device, each representation maybe linked to other representations and cut sheets within the database120 such that facility personnel may navigate through multiplerepresentations and cut sheets, as may be needed when using the system100. As the personnel walks the length of the off-site piping line,geographical data is entered onto the drawing directly or into thecomputer to properly and accurately locate the off-site piping line andpiping objects with respect to its surroundings. As the personnelapproach a cut sheet location, the particular cut sheet is accessed. Thepersonnel then identify the off-site piping line on the appropriate cutsheet. This provides a linking of the cut sheets with the individualplan views of the off-site piping lines. Once a particular off-sitepiping line is walked, the representation is then created. Each pipingobject is identified by a unique identifier and labeled on therepresentation and provided with the appropriate description. If thepiping object appears on multiple representations, the same uniqueidentifier is used to reference that piping object. A description of theoff-site piping line including the discrete substance flowingtherethrough, the facility units connected thereto, other piping linesconnected thereto and the location of the piping objects is prepared.The description may further include information relating to the partywithin the facility responsible for that particular line along withcontact information (i.e., line ownership information). The descriptionmay also include other essential information including but not limitedto the pressure and temperature of the discrete substance flowingthrough the particular piping. Material Safety Data Sheets and HAZMATand HAZOP procedures for the particular substance may also be included.This information will be extremely useful in determining (i) how thematerial is to be handled, and (ii) if an evacuation is necessary in theevent that an emergency event occurs. The descriptions are reviewed andchecked for accuracy and completeness. The information can then be addeddirectly to the representation or linked to the representation. Whenviewed as a hard copy or paper representation, the information may belocated in an appropriate key directly on or adjacent the valve or otherpiping object. In the case of an electronic representation, thedescription may appear in a separate window 143 on the display, asshown, for example in FIGS. 1-14 and 16-18. It is also contemplated thatthe electronic representation may be interactive. With such anarrangement, the person viewing the representation may move a cursor toa particular piping object in display window 141. Locating the cursor onthe piping object or clicking on the piping object may result in adisplay for the particular piping object appearing directly adjacent thepiping object or in an adjacent window on the display, as shown in FIG.8. A separate display window 144 may be opened to display a detailedview of the off-site pipe line 11. Such a display is provided when theoff-site piping line 11 has a complex configuration. Additionaldescriptive for the line and its components may be displayed in a window145 adjacent display window 144.

This descriptive information forms an important aspect of the emergencyisolation and response system 100, described in greater detail below.Using the descriptor information, the facility personnel can quicklyidentify which operating units are connected to a particular off-sitepiping line, which off-site piping lines are linked either directly orindirectly through an operating unit to each other. This information isessential when an emergency response event occurs. If the approximatelocation of the emergency event is determined, the facility personnelcan quickly identify using the cut sheets and off-site piping linesrepresentations, which pipebands, operating units, etc. are impacted bythe event. With this information, the facility personnel can thenidentify which safety measures must be undertaken in order to isolatethe event and determine which operating units, storage tanks, and otheroff-site piping lines are impacted in order to minimize the overallimpact of the event and limit impact on the facility and surroundingcommunity.

Preferably, two dimensional and isometric graphical representations ofthe off-site piping lines are prepared. A sample two dimensionalrepresentation is illustrated in FIG. 4. A sample isometricrepresentation is illustrated in FIG. 8.

In accordance with a preferred embodiment of the present invention, thetwo dimensional and isometric representations and the cut sheets arepreferably maintained in electronic form in a database 120. Theelectronic storage permits easy access by multiple facility personnel.Furthermore, the electronic representations can be easily updated whenmodifications to the off-line piping lines are performed, when operatingunits are operational or not operational. Furthermore, the descriptiveinformation related to line ownership, the substance contained in theline can be easily updated and made available to all facility personnelsuch that the information available to facility personnel is current andaccurate. Additionally, the electronic images can be easily transmittedto the necessary emergency response/management personnel in thesurrounding community in the event that the surrounding community isimpacted by an event (e.g., fire, explosion, release of gas).

The representations and cut sheets are preferably included in asearchable database 120. The database is searchable based upon anynumber of parameters. The database may be searched based upon a lineidentifier to identify a particular line, as shown in search window 142in FIG. 2. The database may be searched by discrete material to identifythose lines containing the discrete substance. The database may besearched by intersection to identify lines and cut sheets located in thevicinity of the intersection. It is also contemplated that the databasemay be searched based upon the owner of the line such that all linesassociated with or under the responsibility of a particular divisionwithin the facility may be identified. It is also contemplated thatindividual representations may be searched to identify a particular lineor lines, or piping object.

In accordance with the present invention, the searchable database 120forms an integral part of an emergency isolation and response system 100for use in the facility. The emergency isolation and response system isinteractive which permits facility personnel to promptly identifyfacility equipment, units and piping lines that may be impacted in theevent of an emergency event, which occurs within the off-site pipingsystem or impacts the off-site piping system, which include but are notlimited to weather related emergencies (i.e., floods, wind, lightning,tornados, hurricanes), fires, explosions or release of toxic materialdue to related to piping failures, spills and other emergency events. Amain objective of the emergency isolation and response system 100 inaccordance with the present invention is to significantly reduce thetime needed to adequately respond to emergency events. This reductionmay permit facility personnel to quickly isolate a particular part ofthe facility, operating unit, etc to contain a spill, fire etc.Furthermore, the isolation of the off-site piping could reduce theescalation of the event, which could result in significant damagethroughout the facility and surrounding areas if left unchecked.Additionally, the system may used to the necessary safety perimeter toprotect facility personnel and the surrounding community.

As shown in FIGS. 15 and 19, the emergency isolation and response systemin accordance with the present invention includes an electronicallysearchable database 120 used in connection with a suitable computeroperating unit 110. The system 100 includes at least one terminal 130operatively connected to the computer operating unit 110 and thedatabase 120. The terminal 130 may be directly connected to the unit 110as a standalone system. Preferably, the terminals 130 are connected tothe unit 110 through a web browser or other suitable connection such asa virtual private network (VPN) 170, as shown in FIG. 19. The terminals130 may also communicate through a wide area network (WAN) 160. Withthese arrangements, multiple users can access the system 100 from theterminals 130. Each terminal 130 includes a monitor with an associatedkeyboard or an interactive touch screen display. The display 140 of themonitor 130 is divided in several areas. A primary display window 141displays aerial images (as shown in FIG. 1), schematic images of thefacility and portions thereof (as shown in FIGS. 2-4, 9 and 10), cutsheets 5 (as shown in FIGS. 5 and 6), and street views (as shown inFIGS. 7 and 11-14). The primary display window 141 can display highlevel representations, as shown for example in FIG. 9. The scale of therepresentations can be adjusted such that more detailed exploded viewsof facility can be displayed, as shown in FIGS. 3, 4, 7, 11-14. A searchwindow 142 permits the user to select and enter desired searchparameters. A description window 143 provides information (e.g., lineowner, substance, maintenance information, etc.) relating to a selectedcut sheet, valve, pipeline, etc. It is contemplated that the computeroperating unit 110 and the database 120 may be located at the facilityor remotely located from the facility for backup purposes, disasterrecovery purposes. A redundant back-up computer operating unit 210 anddatabase 220 may also be remotely located, which serves as a backup inthe event of a failure of the primary system located at the facility.The back-up computer operating unit 210 is connected to the computeroperating unit 110 through the WAN 160, as shown in FIG. 19. In order toensure system integrity, it is contemplated that a limited number offacility personnel will have the ability to modify and/or replacerepresentations, cut sheets and images contained within the system. Allother users of the systems will have read only access to the system,which will permit those users to search, retrieve and review informationbut not change the same. The system 100 is preferably linked to othersystems (e.g., alarm systems, fire and emergency response systems) suchthat information obtained from the system 100 can be easily disseminatedto others. The system 100 may be linked to other modeling systems 180(e.g., dispersion modeling systems, etc.), which can be used to predictthe extent of debris dispersal or potentially toxic clouds in the eventof an emergency event (e.g., explosion). This information may be fedinto the system 100 such that a safety perimeter may be established.

The operation of the emergency isolation and response system inaccordance with the present invention will now be described in greaterdetail in connection with several examples. In the event of theoccurrence of an emergency event associated with a leak in a particularoff-site piping line, the appropriate plant personnel (hereinafterreferred to as a user) access the system 100. The user can search forthe appropriate line using one of several search parameters includingthe line number, the particular line name (which may include adescription of the distinct substance contained therein), theintersection number of the intersection near the leak or a cut sheetnumber.

A search utilizing the line identifier will now be described. The useris presented with a menu, shown in FIG. 2 in search window 142. When theuser enters the identifier associated with the particular off-sitepiping line, the representation of that line is displayed in displaywindow 141, as shown in FIG. 3. The representation includes the locationof piping objects and connections and associated facility systems. In aseparate window 143 on the display area 140, the following informationrelating to the line is displaced: (i) line number; (ii) linedescription; (iii) diameter; (iv) line owner or operator (which may alsoinclude relevant contact information); and (v) relevant cut sheetsidentifiers. A highlighted line 11 is illustrated in FIG. 13. If theuser knows the approximate location of the leak, the user can place anelectronic marker at the approximate location of the leak, as shown inFIG. 13. The system 100 then determines which valves 41 must be operatedin order to isolate the leak. The necessary valves and the portion ofthe impact line are highlighted on the display 141, as shown in FIG. 14,such that the user can notify the necessary facility personnel of theappropriate leak isolation measures. The facility personnel would thenmanually close the valves to isolate the leak. It is also contemplatedthat electronic controls can be provided and linked to the system 100such that the system operator can automatically operate the necessaryvalves. Such an arrangement would be useful when the necessary valve orvalves are located within the safety zone.

The system 100 is interactive. As such, as the facility personnel notifythe user of closure of a valve, the representation can be updated tochange the status of the valve from an open position to a closedposition. This can be used to direct the closure of values in asystematic, less time consuming manner. In some circumstances, a valvemay fail or it is located within a safety zone such that facilitypersonnel can not obtain access to the valve. It is then necessary toidentify secondary valves, which are necessary to isolate the leak. Theuser can change the status of the valve to indicate either a failure orits location within the safety perimeter. As shown in FIG. 13, the usercan then select using search window 142 that secondary valves bedisplayed. It is also possible to identify tertiary valves. Therepresentation is then refreshed to illustrate the secondary valves tobe closed to isolate the leak. Since the secondary or back-up valve isin another location remote from the primary valve, additional operatingunits, etc may be impacted by the shut-off. To differentiate the primaryvalves from the secondary valves, the valves may be displayed indifferent colors or other suitable identifier to distinguish primary andsecondary valves. The display may also highlight those units impacted bythe isolation procedure such that appropriate measures can be taken todivert supply from one line to another to maintain continuous operationof an operating unit or the appropriate shut down measures can be takento avoid failure of an operating unit or to minimize damage to otherpiping objects within the particular off-site piping lines or adjacentpiping lines.

A search utilizing an off-site piping line description will now bedescribed. The facility personnel may not know the particular lineidentifier, but may know the discrete substance flowing there through orthe line name. The user using a pull down screen 146 may obtain a listof line numbers with a description of the line, the distinct substanceflowing therethrough, etc. The pull down screen 146 is illustrated inFIG. 9. For purposes of illustration the specific line identifierinformation has been omitted from the window 146. In operation, the usercan highlight the desired line identifier to display the correspondingrepresentation in window 141. The user could also perform a search basedupon the substance to provide a listing of potential off-site pipelines. Based upon the information, the user can quickly isolate andidentify certain off-site piping lines, which fit the descriptionsprovided by the facility personnel. From the listing, the user canretrieve the representations for display in the primary display window141. As described above, the representation includes the location of allvalves, diverters, connections and other piping objects. In a separatewindow 143 on the display area, the following information relating tothe line is displaced: (i) line number; (ii) line description; (iii)diameter; (iv) line owner or operator; (v) relevant cut sheetsidentifiers; and (vi) other connected systems. If the user knows theapproximate location of the leak, the user can highlight the particulararea to produce an enlarged view. The leak can then be contained in themanner described above.

A search utilizing a cut sheet identifier will now be described. Thefacility personnel may provide the user with the unique identifierassociated with a particular cut sheet. The user can then search for thecut sheet whereby the particular cut sheet is displayed, a shown in FIG.5. From the cut sheet, the user can identify the identifier of theparticular off-site piping line. The user may either highlight thedesired cross section of the piping line on the cut sheet or enter theline identifier to highlight a particular piping line, as shown in FIG.6. The user can then retrieve the necessary representation illustratinga particular off-site piping line. The user can then notify the facilitypersonnel of the appropriate measures and steps necessary to isolate theleak.

A search utilizing a street or intersection identifier will now bedescribed. A situation may arise when the facility personnel calling inan emergency event is not familiar with the particular pipeband or thelines contained therein. The facility personnel may provide the userwith only the street name or the intersection identifier or othergeographic identifier such as adjacent operating units. Geographicidentifiers can also be used in the event a member of the surroundingcommunity calls in an event to the facility. The user can then searchfor the street and/or intersection and/or operating from a pull downmenu 147 in search window 142. The pull down menu 147 is illustrated inFIG. 10. For purposes of illustration the specific location identifierinformation has been omitted from the menu 147. In operation, the usercan highlight the desired line identifier to display the correspondingrepresentation in window 141. Upon selection of a particularintersection, for example, a representation of the intersection isdisplayed, as shown in FIG. 7. The representation identifies thelocation of the nearest cut sheets 5, as shown in FIG. 11 and 12. Theuser can then identify the particular pipeband. Upon identifying theparticular pipeband, the user can then identify the relevant cut sheet5. The user can then either select the cut sheet marker displayed (byhighlighting or clicking on the marker, as shown in FIG. 6) or enter theappropriate identifier associated with the cut sheet in the searchwindow 142 to then display the necessary cut sheet. Once the appropriateoff-site piping line is identified on the cut sheet, as shown in FIG. 6,the user can either highlight the particular line, as shown in FIG. 6,or enter the identifier corresponding to the line in the search window142 to then display the appropriate line display. The linerepresentation can then be displayed, as shown in FIG. 13. The user canthen notify the facility personnel of the appropriate measures and stepsnecessary to isolate the leak.

The emergency isolation and response system 100 in accordance with thepresent invention may also be used to highlight an area within aparticular perimeter, as shown in FIGS. 1 and 16. For example, inresponse to the occurrence of an emergency event (e.g., spill, fire,explosion, toxic event) within the facility it may be necessary toidentify those off-site piping lines located within a safety perimeter.The user can retrieve an aerial image, as shown in FIG. 1, or largescale representation of the facility to pinpoint the approximatelocation of the event. The user can either draw a trace 30 or enter theapproximate radius of the security perimeter, as shown in FIG. 1. Theuser can then retrieve an image, which enlarges the traced area, asshown in FIG. 16. The enlarged representation then identifies theoff-site piping lines, the piping objects, operating units and otheridentifiers contained within the perimeter. The user can then retrieverepresentations of the off-site piping lines to determine which if anyof the lines and the operating units, etc. connected thereto areimpacted. The user can then retrieve the necessary piping objectinformation, etc such that the impact of the emergency event can belimited to the area within the safety perimeter. This is very effectiveto minimize the potential catastrophic impact of an emergency event. Thesystem can also be used to identify the necessary size of a safetyperimeter. Unfortunately, explosions, fires and the release of flammableor toxic gases from operating units do occur. When this does occur, itmay be necessary to evacuate persons from buildings within the facilitythe community surrounding the facility. While other methods areavailable for estimating the spread of such releases throughout thefacility and beyond the facility perimeter, the results of suchestimated can be integrated with the system 100 and the extent displayedon the facility representation, as shown, for example, in FIG. 1. Byexpanding the aerial images to the surround community, it is possible toidentify the scope of any mandatory evacuation. As discussed above, thesystem 100 may be linked to other systems. It is possible to link thesystem 100 to an alarm system such that alarms may sound within thesafety perimeter to notify facility personnel to leave the area. Thesafety perimeter may also be used to establish a safety perimeter formaintenance and other non-emergency events. For example, a crane may beused to lift refinery components over pipe bands and other componentswithin the facility. The height of the crane can be used to establish asafety perimeter in the event that the crane topples.

The system 100 can also be used to identify all off-site piping lines,which extend through a pipeband. The user can identify a particularpipeband by identifying two points (which create a cross sectional line191) over a pipeband, as shown in FIG. 17. The system 100 then searchesand identifies all off-site piping lines passing through the pipeband atthat location. The relevant information relating to each of the off-sitepiping lines is then displayed in a list, as shown for example in FIG.18, which for purposes of illustration displays the window, but not thespecific contents. The actual display window would display sufficientinformation such that the user can readily identify and select thenecessary piping lines. The displayed information includes links, whichpermit the user to then quickly locate representations and cut sheetsassociated with the individual off-site piping lines contained withinthe pipeband. This functionality is especially useful when an eventoccurs that may impact an entire pipeband. As such, all of the affectedlines within the pipe band can be identified such that sufficientisolation steps can be performed for each line to isolate the event.

It is also contemplated that the system 100 may be linked to anautomated leak detection system, which could detect pressure drops andother parameters indicative of leaks. The system 100 can then be used topinpoint the leak and identify the necessary steps (e.g., valveclosures) needed to isolate the event.

While the primary objective of the emergency isolation and responsesystem is directed to improving response times in emergency events, thesystem 100 is useful other purposes, which are considered to be wellwithin the scope of the present invention. The system 100 can be used asa training module for facility personnel in connection to with emergencyresponse planning and preparation. The system 100 can be used tosimulate the occurrence of an emergency event to facilitate preparednessof both facility personnel and those in the surrounding community.

It is also contemplated that the system 100 can be used in connectionwith planning. As a planning tool, the system 100 can be used toidentify (i) unused off-site piping lines, (ii) which lines andoperating units are impacted by maintenance procedures, (iii) lines andoperating units that are impacted when components are lifted over apipeband, (iv) possible locations of new off-site piping lines, (v)managing the inspection of off-site piping systems, and (vi) managingthe maintenance of off-site piping systems.

The present invention, however, is not intended to be limited to justoff-site piping; rather, it is contemplated that the system 100 can beused in connection with processing units to track and isolate events inprocessing units. It is also contemplated that usage of the system 100will be stored in memory in the computer control unit 110 such thatcertain information can be later retrieved, if necessary. In particular,date, time and user accessing the representation is stored includingcopies of the representation and any changes made (i.e., the actuationof valves) in response to an event or use of the system 100.

It will be apparent to those skilled in the art that variousmodifications and/or variations may be made without departing from thescope of the present invention. It is intended that all matter containedin the accompanying specification shall be interpreted as illustrativeonly and not in a limiting sense. While the present invention has beendescribed in the context of a refinery and/or petrochemical facility,the present invention is not intended to be so limited; rather it iscontemplated that the present invention is suitable for use in otherfacilities having extending lines of piping for transporting materialsthroughout a facility. Thus, it is intended that the present inventioncovers the modifications and variations of the method and systemdisclosed herein, provided the modifications and variation come withinthe scope of the appended claims and their equivalents.

1. A method for mapping a facility having at least one facility unit anda piping system, wherein the piping system includes at least onepipeband extending through at least a portion of the facility, eachpipeband contains at least one piping line through which a designatedsubstance flows there through and at least one piping line deviceassociated therewith, comprising: locating and identifying select landbased identifiers within the facility and assigning a uniqueintersection identifier for each of the select land based identifiersand providing descriptive information for each of the select land basedidentifiers, wherein each of the select land based identifiers beinglocated in the vicinity of one of the at least one facility unit and apiping system; locating and identifying at least one location for atleast one cut sheet in the vicinity of at least one of the select landbased identifiers and assigning a unique cut sheet identifier for eachlocation of a cut sheet, wherein each cut sheet is located adjacent tothe piping system and identifies each piping line at the location of thecut sheet; mapping each of the least one cut sheet to identify eachpiping line within the pipeband at the location of the particular cutsheet, wherein the mapping of each cut sheet includes identifying eachpiping line at the location of the particular cut sheet and locationwithin the pipeband; and mapping each of the at least one piping line,wherein mapping each piping line includes (i) assigning a unique pipingline identifier for the piping line, (ii) providing descriptiveinformation for the piping line, (iii) identifying each piping linedevice associated with the piping line, (iv) providing descriptioninformation for each piping line device, (v) mapping the location ofeach piping line device associated with the piping line, (vi) providinga unique descriptive identifier for each piping device, and (vii)mapping at least one of the location of each cut sheet location on eachpiping line and the location of each piping line on each cut sheetlocation.
 2. The method of mapping according to claim 1, furthercomprising: obtaining at least one image of the facility, wherein the atleast one image identifies approximate locations of the at least oneoff-site pipeband, the at least one facility unit, and the at least oneland based identifier.
 3. The method of mapping according to claim 1,wherein the piping line is one of off-site piping line and on-sitepiping line.
 4. The method of mapping according to claim 1, wherein theat least one piping line device comprising at least one of a valve,piping object, sensor, and monitoring device.
 5. The method of mappingaccording to claim 1, wherein the mapping of each of the at least onecut sheet includes preparing an electronic representation of each cutsheet.
 6. The method of mapping according to claim 5, wherein themapping of each of the at least one piping line includes preparing anelectronic representation of each piping line.
 7. The method of mappingaccording to claim 6, further comprising: providing at least oneelectronic link between each piping line represented on a particular cutsheet and the electronic representation corresponding to such pipingline.
 8. The method of mapping according to claim 1, wherein the mappingeach cut sheet includes providing a directional indicator orienting thecut sheet with respect to at least one select land based identifier. 9.The method of mapping according to claim 1, providing descriptiveinformation for the piping line includes providing the diameter of thepiping line.
 10. The method of mapping according to claim 1, wherein themapping each of the least one cut sheet to identify each piping lineincludes identifying the diameter of each piping line at the location ofthe particular cut sheet.
 11. A system for emergency isolation andresponse to an event in a facility, wherein the facility includes apiping system having at least one pipeband extending across a portion ofthe facility, wherein each pipeband contains at least one piping line,wherein each piping line containing piping through which a substanceflows therethough and at least one piping line device, wherein thefacility includes at least one facility unit, comprising: a searchabledatabase containing at least one representation of each piping line, andat least one cut sheet for each of the at least one pipeband, whereineach cut sheet illustrating the at least one piping line extendingthrough the pipeband at the particular location of the cut sheet in thefacility and the location of the piping line with respect to otherpiping lines within the pipeband at the particular location of the cutsheet, wherein each representation of a piping line is electronicallylinked to the each cut sheet in which such piping line appears, whereineach cut sheet is electronically linked to each representation of apiping line within the pipeband at the particular location of the cutsheet; a computer operating unit for storing the searchable database andretrieving representations and cut sheets; at least one terminal foraccessing and displaying representations and cut sheets retrieved by thecomputer operating unit.
 12. The system according to claim 11, whereineach of the at least one piping line is one of an off-site piping lineand an on-site piping line.
 13. The system according to claim 11,further comprising: at least one representation of a cut sheet, whereinthe at least one representation of the cut sheet is displayed at theparticular location of the cut sheet in the facility.